Electrospun fibers having contrast agents and methods of making the same

Abstract

A fiber may comprise an electrospun polymer and a contrast agent. A method of making an electrospun fiber may comprise configuring a receiving surface to receive a polymer fiber, applying a charge to one or more of the receiving surface, a polymer injection system, and a polymer solution ejected from the polymer injection system, and depositing a polymer solution ejected from the polymer injection system onto the receiving surface. The polymer solution may comprise a polymer and a contrast agent.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefit of U.S. Provisional Application Ser. No. 62/249,640, filed Nov. 2, 2015, entitled “Electrospun Fibers Having Contrast Agents And Methods Of Making The Same,” which is hereby incorporated herein by reference in its entirety.

BACKGROUND

Polymer fibers may be useful for the repair, replacement, or treatment of any organ or tissue within the body, or for the proliferation or differentiation of cells outside the body. Such fibers must be biocompatible so that the body or cells do not reject them, and so that they do not create damaging inflammation. Electrospinning is one method of fabricating such fibers while finely controlling their properties and orientation. In some instances, it may be useful for these fibers to be visualized before, during, and after they are implanted, inserted, or otherwise placed in the body. Fibers with radiopaque properties may be advantageous in these instances. In particular, there exists a need for electrospun polymer fibers with one or more contrast agents dispersed therein, which allows the fibers to be visualized before, during, and after implantation.

SUMMARY

The present disclosure is directed to electrospun fibers having contrast agents, and methods of making such fibers.

In some embodiments, a fiber may comprise an electrospun polymer and a contrast agent. The contrast agent may be dispersed throughout the fiber. In some embodiments, the contrast agent may comprise a powder.

In some embodiments, a method of making an electrospun fiber may comprise configuring a receiving surface to receive a polymer fiber, applying a charge to one or more of the receiving surface, a polymer injection system, and a polymer solution ejected from the polymer injection system, and depositing a polymer solution ejected from the polymer injection system onto the receiving surface. The polymer solution may comprise a polymer and a contrast agent.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a photograph of fibers comprising an electrospun polymer and a contrast agent in accordance with an embodiment of the present disclosure.

FIG. 1B is an x-ray of the fibers shown in FIG. 1A, showing more contrast on the leftmost thread, no contrast on the middle thread, and less contrast on the rightmost thread compared to a metal stent in the bottle, in accordance with an embodiment of the present disclosure.

FIG. 2 is an x-ray of fiber sheets comprising barium sulfate and tungsten sulfate in different concentrations, in accordance with an embodiment of the present disclosure. From top to bottom, the x-ray illustrates fiber sheets with concentrations of 40 wt %, 100 wt % (i.e. 1:1), 200 wt % (i.e. 1:2), 300 wt %, 400 wt %, 100 wt %, and 50 wt % (i.e. 2:1) of a combination of barium sulfate and tungsten sulfate based on the weight of the polymer.

FIG. 3 is an x-ray of fiber sheets comprising different concentrations of barium sulfate, in accordance with an embodiment of the present disclosure. From top to bottom, the x-ray illustrates fiber sheets with concentrations of 1 wt %, 5 wt %, 10 wt %, 20 wt %, 40 wt %, 60 wt %, 80 wt %, and 100 wt % of barium sulfate based on the weight of the polymer.

FIG. 4 is an x-ray of fiber sheets comprising barium sulfate and meglumine diatrizoate in different concentrations compared to platinum aneurysm coils, in accordance with an embodiment of the present disclosure.

FIG. 5 is a scanning electron microscope (SEM) image of a fiber comprising a polymer and 100 wt % bismuth based on the weight of the polymer, in accordance with an embodiment of the present disclosure.

FIG. 6 is a scanning electron microscope (SEM) image of a fiber comprising a polymer and 400 wt % bismuth based on the weight of the polymer, in accordance with an embodiment of the present disclosure.

FIG. 7 graphically illustrates a comparison of the ultimate tensile strength (UTS, in MPa) of a fiber comprising polycaprolactone (PCL), and a fiber comprising PCL and 400 wt % bismuth (Bi₂O₃) based on the weight of the PCL, in accordance with an embodiment of the present disclosure.

FIG. 8 graphically illustrates a comparison of the modulus of a fiber comprising PCL, and a fiber comprising PCL and 400 wt % Bi₂O₃ based on the weight of the PCL, in accordance with an embodiment of the present disclosure.

FIG. 9 graphically illustrates a comparison of the elongation (%) of a fiber comprising PCL, and a fiber comprising PCL and 400 wt % bismuth Bi₂O₃ based on the weight of the PCL, in accordance with an embodiment of the present disclosure.

FIG. 10 graphically illustrates the engineering stress vs. elongation (%) of a five sample test set of an electrospun fiber comprising an unfilled 2:8 blend of polyethylene terephthalate and polyurethane.

FIG. 11 graphically illustrates the engineering stress vs. elongation (%) of a five sample test set of an electrospun fiber comprising a 2:8 blend of polyethylene terephthalate and polyurethane filled with 1,000 wt % of tantalum, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the disclosure.

The following terms shall have, for the purposes of this application, the respective meanings set forth below. Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.

As used herein, the singular forms “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise. Thus, for example, reference to a “fiber” is a reference to one or more fibers and equivalents thereof known to those skilled in the art, and so forth.

As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50 μm means in the range of 45 μm to 55 μm.

Electrospinning

Electrospinning is a method which may be used to process a polymer solution into a fiber. In embodiments wherein the diameter of the resulting fiber is on the nanometer scale, the fiber may be referred to as a nanofiber. Fibers may be formed into a variety of shapes by using a range of receiving surfaces, such as mandrels, molds, or collectors. The resulting fiber molds or shapes may be used in many applications, including the repair or replacement of biological structures. In some embodiments, the resulting fiber or fiber scaffold may be implanted into a biological organism or a portion thereof.

Electrospinning methods may involve spinning a fiber from a polymer solution by applying a high DC voltage potential between a polymer injection system and a receiving surface. In some embodiments, one or more charges may be applied to one or more components of an electrospinning system. In some embodiments, a charge may be applied to the receiving surface, the polymer injection system, the polymer solution, or combinations or portions thereof. Without wishing to be bound by theory, as the polymer solution is ejected from the polymer injection system, it is thought to be destabilized due to its exposure to a charge. The destabilized solution may then be attracted to a charged receiving surface. As the destabilized solution moves from the polymer injection system to the receiving surface, its solvents may evaporate and the polymer may stretch, leaving a long, thin fiber that is deposited onto the receiving surface. The polymer solution may form a Taylor cone as it is ejected from the polymer injection system and exposed to a charge.

Polymer Injection System

A polymer injection system may include any system configured to eject some amount of a polymer solution into an atmosphere to permit the flow of the polymer solution from the injection system to the receiving surface. In some embodiments, the polymer injection system may deliver a continuous or linear stream with a controlled volumetric flow rate of a polymer solution to be formed into a fiber. In some embodiments, the polymer injection system may deliver a variable stream of a polymer solution to be formed into a fiber. In some embodiments, the polymer injection system may be configured to deliver intermittent streams of a polymer solution to be formed into multiple fibers. In some embodiments, the polymer injection system may include a syringe under manual or automated control. In some embodiments, the polymer injection system may include multiple syringes and multiple needles or needle-like components under individual or combined manual or automated control. In some embodiments, a multi-syringe polymer injection system may include multiple syringes and multiple needles or needle-like components, with each syringe containing the same polymer solution. In some embodiments, a multi-syringe polymer injection system may include multiple syringes and multiple needles or needle-like components, with one or more syringes containing one or more different polymer solutions. In some embodiments, a charge may be applied to the polymer injection system, or to a portion thereof. In some embodiments, a charge may be applied to a needle or needle-like component of the polymer injection system.

In some embodiments, the polymer solution may be ejected from the polymer injection system at a flow rate per needle of less than or equal to about 5 mL/h. Some non-limiting examples of flow rates per needle may include about 0.1 mL/h, about 0.5 mL/h, about 1 mL/h, about 1.5 mL/h, about 2 mL/h, about 2.5 mL/h, about 3 mL/h, about 3.5 mL/h, about 4 mL/h, about 4.5 mL/h, about 5 mL/h, or ranges between any two of these values, including endpoints. As the polymer solution travels from the polymer injection system toward the receiving surface, the diameter of the resulting fibers may be in the range of about 0.1 μm to about 10 μm. Some non-limiting examples of electrospun fiber diameters may include about 0.1 μm, about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, or ranges between any two of these values, including endpoints.

Polymer Solution

In some embodiments, the polymer injection system may be filled with a polymer solution. In some embodiments, the polymer solution may comprise one or more polymers. In some embodiments, the polymer solution may be a fluid formed into a polymer liquid by the application of heat. A polymer solution may include synthetic or semi-synthetic polymers such as, without limitation, polyethylene terephthalate (PET), polyester, polymethylmethacrylate, polyacrylonitrile, silicone, polyurethane, polycarbonate, polyether ketone ketone, polyether ether ketone, polyether imide, polyamide, polystyrene, polyether sulfone, polysulfone, polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), polycaprolactone (PCL), polylactic acid (PLA), polylactide co-caprolactone, polylactide co-glycolide, polyglycolic acid (PGA), polyglycerol sebacic, polydiol citrate, polyhydroxy butyrate, polyether amide, polydioxanone, and combinations or derivatives thereof. In some embodiments, polyhydroxyalkanoates, specifically poly-4-Hydroxybutyrate, may be excluded from the polymer solution described herein. Alternative polymer solutions used for electrospinning may include natural polymers such as fibronectin, collagen, gelatin, hyaluronic acid, chitosan, or combinations thereof. It may be understood that polymer solutions may also include a combination of synthetic polymers and naturally occurring polymers in any combination or compositional ratio. In some non-limiting examples, the polymer solution may comprise a weight percent ratio of, for example, polyethylene terephthalate to polyurethane, from about 10% to about 90%. Non-limiting examples of such weight percent ratios may include 10%, 25%, 33%, 50%, 66%, 75%, 90%, or ranges between any two of these values, including endpoints.

In some embodiments, the polymer may be present in an amount of about 1 wt % to about 30 wt % based on the weight of the polymer solution. In some non-limiting examples, the polymer may be present in the amount of, for example, about 1 wt %, about 2 wt %, about 3 wt %, about 4 wt %, about 5 wt %, about 6 wt %, about 7 wt %, about 8 wt %, about 9 wt %, about 10 wt %, about 11 wt %, about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %, about 16 wt %, about 17 wt %, about 18 wt %, about 19 wt %, about 20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, about 25 wt %, about 26 wt %, about 27 wt %, about 28 wt %, about 29 wt %, about 30 wt %, or ranges between any two of these values, including endpoints.

In some embodiments, the polymer solution may comprise one or more solvents. In some embodiments, the solvent may comprise, for example, acetone, dimethylformamide, dimethylsulfoxide, N-methylpyrrolidone, acetonitrile, hexanes, ether, dioxane, ethyl acetate, pyridine, toluene, xylene, tetrahydrofuran, trifluoroacetic acid, hexafluoroisopropanol, acetic acid, dimethylacetamide, chloroform, dichloromethane, water, alcohols, ionic compounds, or combinations thereof. The concentration range of polymer or polymers in solvent or solvents may be, without limitation, from about 1 wt % to about 50 wt %. Some non-limiting examples of polymer concentration in solution may include about 1 wt %, 3 wt %, 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about 40 wt %, about 45 wt %, about 50 wt %, or ranges between any two of these values, including endpoints.

In some embodiments, the polymer solution may also include additional materials. Non-limiting examples of such additional materials may include radiation opaque materials, contrast agents, electrically conductive materials, fluorescent materials, luminescent materials, antibiotics, growth factors, vitamins, cytokines, steroids, anti-inflammatory drugs, small molecules, sugars, salts, peptides, proteins, cell factors, DNA, RNA, or any other materials to aid in non-invasive imaging, or any combination thereof. In some embodiments, the electrically conductive materials may include, for example, gold, silver, iron, polyaniline, carbon black, polyacrylonitrile, graphene, or combinations thereof.

In some embodiments, the contrast agents may include, for example, barium, tantalum, tungsten, platinum, gold, bismuth, iodine, gadolinium, diatrizoate, metrizoate, ioxaglate, iopamidol, iohexol, ioxilan, iopromide, iodixanol, derivatives thereof, oxides thereof, salts thereof, or combinations thereof. In some embodiments, the contrast agent may be dispersed in a solution different from the polymer solution described in other embodiments herein. In some embodiments, the contrast agent may be dispersed in the polymer solution. In other embodiments, the contrast agent can be dispersed in a separate solution prior to being added to the polymer solution. In some embodiments, the contrast agent may comprise a powder. In some embodiments, the powder may comprise particles having a diameter from about 10 nm to about 10 μm. In some embodiments, the powder may comprise particles having a diameter of, for example, about 10 nm, about 20 nm, about 30 nm, about 40 nm, about 50 nm, about 60 nm, about 70 nm, about 80 nm, about 90 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, or ranges between any two of these values, including endpoints.

The type of polymer in the polymer solution may determine the characteristics of the electrospun fiber. Some fibers may be composed of polymers that are bio-stable and not absorbable or biodegradable when implanted. Such fibers may remain generally chemically unchanged for the length of time in which they remain implanted. Alternatively, fibers may be composed of polymers that may be absorbed or biodegraded over time. Such fibers may act as an initial template or scaffold for the repair or replacement of organs and/or tissues. These organ or tissue templates or scaffolds may degrade in vivo once the tissues or organs have been replaced or repaired by natural structures and cells. It may be further understood that a polymer solution and its resulting electrospun fiber(s) may be composed of more than one type of polymer, and that each polymer therein may have a specific characteristic, such as bio-stability or biodegradability.

Applying Charges to Electrospinning Components

In an electrospinning system, one or more charges may be applied to one or more components, or portions of components, such as, for example, a receiving surface, a polymer injection system, a polymer solution, or portions thereof. In some embodiments, a positive charge may be applied to the polymer injection system, or portions thereof. In some embodiments, a negative charge may be applied to the polymer injection system, or portions thereof. In some embodiments, the polymer injection system, or portions thereof, may be grounded. In some embodiments, a positive charge may be applied to the polymer solution, or portions thereof. In some embodiments, a negative charge may be applied to the polymer solution, or portions thereof. In some embodiments, the polymer solution, or portions thereof, may be grounded. In some embodiments, a positive charge may be applied to the receiving surface, or portions thereof. In some embodiments, a negative charge may be applied to the receiving surface, or portions thereof. In some embodiments, the receiving surface, or portions thereof, may be grounded. In some embodiments, one or more components or portions thereof may receive the same charge. In some embodiments, one or more components, or portions thereof, may receive one or more different charges.

The charge applied to any component of the electrospinning system, or portions thereof, may be from about −15 kV to about 30 kV, including endpoints. In some non-limiting examples, the charge applied to any component of the electrospinning system, or portions thereof, may be about −15 kV, about −10 kV, about −5 kV, about −3 kV, about −1 kV, about −0.01 kV, about 0.01 kV, about 1 kV, about 5 kV, about 10 kV, about 12 kV, about 15 kV, about 20 kV, about 25 kV, about 30 kV, or any range between any two of these values, including endpoints. In some embodiments, any component of the electrospinning system, or portions thereof, may be grounded.

Receiving Surface Movement During Electrospinning

During electrospinning, in some embodiments, the receiving surface may move with respect to the polymer injection system. In some embodiments, the polymer injection system may move with respect to the receiving surface. The movement of one electrospinning component with respect to another electrospinning component may be, for example, substantially rotational, substantially translational, or any combination thereof. In some embodiments, one or more components of the electrospinning system may move under manual control. In some embodiments, one or more components of the electrospinning system may move under automated control. In some embodiments, the receiving surface may be in contact with or mounted upon a support structure that may be moved using one or more motors or motion control systems. The pattern of the electrospun fiber deposited on the receiving surface may depend upon the one or more motions of the receiving surface with respect to the polymer injection system. In some embodiments, the receiving surface may be configured to rotate about its long axis. In one non-limiting example, a receiving surface having a rotation rate about its long axis that is faster than a translation rate along a linear axis may result in a nearly helical deposition of an electrospun fiber, forming windings about the receiving surface. In another example, a receiving surface having a translation rate along a linear axis that is faster than a rotation rate about a rotational axis may result in a roughly linear deposition of an electrospun fiber along a liner extent of the receiving surface.

Electrospun Fibers Having Contrast Agents

In some embodiments, a fiber may comprise an electrospun polymer and a contrast agent. In some embodiments, a fiber may have a contrast agent dispersed therein. In one embodiment, the fiber includes a contrast agent dispersed within the electropsun polymer. In certain embodiments, the contrast agent is dispersed within the electrospun polymer and excludes contrast agents present only on the outer surface of a fiber formed from the electrospun polymer. Such embodiments exclude dipping, spraying or otherwise treating the outside surface of a fiber with contrast agents. Contrast agents dispersed within the electrospun polymer provide the added benefit of being resistant to accidental or unanticipated removal of the contrast agent from the fiber.

In some embodiments, the electrospun polymer may comprise one or more polymers. In some embodiments, the polymers may include, without limitation, the polymers described above. In some embodiments, polyhydroxyalkanoates, specifically poly-4-Hydroxybutyrate, may be excluded from the polymer solution described herein. It may be understood that polymers may also include a combination of synthetic polymers and naturally occurring polymers in any combination or compositional ratio.

In some embodiments, the contrast agent may comprise, for example, barium, tantalum, tungsten, platinum, gold, bismuth, iodine, gadolinium, diatrizoate, metrizoate, ioxaglate, iopamidol, iohexol, ioxilan, iopromide, iodixanol, derivatives thereof, oxides thereof, salts thereof, or combinations thereof. In some embodiments, the contrast agent may comprise a powder. In some embodiments, the contrast agent may be dispersed in a solution. In some embodiments, the powder may be dispersed in a solution. In some embodiments, the powder may comprise particles having a diameter from about 10 nm to about as described above. In other embodiments, the powder may comprise particles having a diameter from about 10 nm to about 10 μm.

In some embodiments, the contrast agent may be present in an amount of about 10 wt % to about 500 wt %, based on the weight of the polymer. The term “wt %” as used herein refers to the percent weight of the identified material based on the total weight of a formulation containing the identified material. For example, a contrast agent being present in an amount of about 500 wt %, based on the weight of a polymer equates to a final formulation where the concentration of the contrast agent is five times greater than the total weight of the polymer. In one embodiment, the contrast agent may be present in an amount of about 10 wt % to about 2,000 wt %. In some embodiments, the contrast agent may be present in an amount of about 500 wt % to about 2,000 wt %. In another embodiment, the contrast agent may be present in an amount of about 750 wt % to about 1,500 wt %. In one embodiment, the contrast agent is present in an amount of about 900 wt % to about 1,100 wt %. In other embodiments, the contrast agent may be present in an amount of about 850 wt % to about 1,150 wt %. In some embodiments, the contrast agent may be present in an amount of, for example, about 10 wt %, about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt %, about 100 wt %, about 125 wt %, about 150 wt %, about 175 wt %, about 200 wt %, about 225 wt %, about 250 wt %, about 275 wt %, about 300 wt %, about 325 wt %, about 350 wt %, about 375 wt %, about 400 wt %, about 425 wt %, about 450 wt %, about 475 wt %, about 500 wt %, about 525 wt %, about 550 wt %, about 575 wt %, about 600 wt %, about 625 wt %, about 650 wt %, about 675 wt %, about 700 wt %, about 725 wt %, about 750 wt %, about 775 wt %, about 800 wt %, about 825 wt %, about 850 wt %, about 875 wt %, about 900 wt %, about 925 wt %, about 950 wt %, about 975 wt %, about 1,000 wt %, about 1,100 wt %, about 1,200 wt %, about 1,300 wt %, about 1,400 wt %, about 1,500 wt %, about 1,600 wt %, about 1,700 wt %, about 1,800 wt %, about 1,900 wt %, about 2,000 wt %, or ranges between any two of these values, including endpoints, based on the weight of the polymer. In some embodiments, the contrast agent may be present in an amount of greater than about 100 wt %, greater than about 150 wt %, greater than about 200 wt %, greater than about 250 wt %, greater than about 300 wt %, greater than about 350 wt %, greater than about 400 wt %, greater than about 450 wt %, greater than about 500 wt %, greater than about 600 wt %, greater than about 700 wt %, greater than about 800 wt %, greater than about 900 wt %, greater than about 1,000 wt %, greater than about 1,500 wt %, greater than about 2,000 wt % or ranges between any two of these values, including endpoints, based on the weight of the polymer. In one embodiment, the contrast agent is present in an amount of about 1,000 wt %.

Electrospinning polymers including contrast agents provides a mechanism to include high concentrations of contrast agent within a fiber formed from the polymers. Other processing methods, such as extrusion techniques, are limited in the amount of solids that can be present within the extruded polymer. Since extruded polymers require some degree of mechanical integrity in order to withstand the extruding process, extruded polymers cannot hold high concentrations of solids. An extruded polymer having a high solids content will exhibit an increase in viscosity and/or will result in a final extruded product having no, or poor, mechanical integrity. In contrast, the electrospun fibers disclosed herein are capable of being formed from electrospun polymers having a high solids content (i.e., particle loading level) while at the same time providing an electrospun fiber having a high degree of mechanical integrity, as demonstrated, for example, in FIGS. 7, 8, and 9. Electrospun polymers, as described herein, may be loaded with a high concentration of particles, including contrast agents. Examples of such high loading concentrations are disclosed herein. The high loading concentrations of the electrospun polymers unexpectedly result in a fiber that maintains sufficient tensile strength, modulus, and elongation as compared to a fiber produced via a typical melt process, i.e., extruding, which suffers extreme loss of strength and elongation. For example, in one embodiment, an electrospun polymer described herein can be loaded with about 1,000 wt % of particles, resulting in a fiber that maintains sufficient tensile strength, modulus, and elongation. Typical melt-processing techniques are limited in the amount of filler that can be present in a polymer before suffering losses in mechanical integrity in an extruded product. For example, increases in filler content of a typical PVC formulation have been shown to decrease the extension at break and tensile strength (See Deshmukh. S. P et al., “Effects of Particle Size and Concentration on Mechanical and Electrical Properties of the Mica Filled PVC,” Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No. 9, pp. 831-844 (2010)). Further, thermoset systems also illustrate a decrease in tensile strength and elongation (%) with increasing filler content (See Ozsoy, Iskender et al., “The Influence of Miro- and Nano-Filler Content on the Mechanical Properties of Epoxy Composites,” Journal of Mechanical Engineering, 61.10, pp. 601-609 (2015)). Typical melt process systems have been shown to have the best synthetic properties at about a 25% filler load, after which the synthetic properties vastly erode (See Zhang, S. et al. “The effects of particle size and content on the thermal conductivity and mechanical properties of Al₂O₃/high density polyethylene (HDPE) composites,” eXPRESS Polymer Letters, Vol. 5, No. 7, pp. 581-590 (2011)). Thus, filler loadings of typical melt process polymers of over around 25%-50 wt % have been shown to negatively affect impact strength, elongation and other mechanical properties of typical melt-process polymeric systems. In contrast, it has been observed that fibers according to an embodiment of the instant disclosure, i.e., fibers made from electrospun polymers having high concentrations of filler (including contrast agents), retain mechanical sufficient mechanical integrity that is unexpected in view of the prior art melt-process systems. In addition, an electrospun polymer having a high concentration of contrast agent results in a fiber being highly visible when viewed non-invasively with an imaging method such as X-ray or fluoroscopy, for example. Therefore, in some embodiments, it is desirable to maximize the concentration of the contrast agent in the electrospun polymers. In some embodiments, the contrast agent may be present an amount that maximizes the concentration of the contrast agent in the electrospun polymer while at the same time retaining the integrity of a fiber formed from the polymer solution.

In some embodiments, the contrast agent may allow the fiber to be viewed and monitored with standard radiological imaging techniques, such as, for example, X-ray, fluoroscopy, ultrasound, optical coherence tomography (OCT), computed tomography (CT), magnetic resonance imaging (MRI), or positron emission tomography (PET), before, during, and following its insertion into body or tissue.

In some embodiments, the fiber may further comprise one or more of an electrically conductive material, a fluorescent material, a luminescent material, an antibiotic, a growth factor, a vitamin, a cytokine, a steroid, an anti-inflammatory drug, a small molecule, a sugar, a salt, a peptide, a protein, a cell factor, DNA, RNA, or a combination thereof. In some embodiments, the electrically conductive material may comprise, for example, gold, silver, iron, polyaniline, carbon black, polyacrylonitrile, graphene, or a combination thereof.

In some embodiments, the fiber may have a length from about 5 μm to about 5 m. In some embodiments, the fiber may have a length of, for example, about 5 μm, about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 150 μm, about 200 μm, about 250 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 5 mm, about 10 mm, about 20 mm, about 30 mm, about 40 mm, about 50 mm, about 60 mm, about 70 mm, about 80 mm, about 90 mm, about 100 mm, about 150 mm, about 200 mm, about 250 mm, about 300 mm, about 350 mm, about 400 mm, about 450 mm, about 500 mm, about 550 mm, about 600 mm, about 650 mm, about 700 mm, about 750 mm, about 800 mm, about 850 mm, about 900 mm, about 950 mm, about 2 m, about 2 m, about 3 m, about 4 m, about 5 m, or ranges between any two of these values, including endpoints.

In some embodiments, the fiber may have a diameter of about 50 nm to about 50 μm. In some embodiments, the fiber may have a diameter of, for example, about 50 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, or ranges between any two of these values, including endpoints.

In some embodiments, the fiber may be formed into a shape such as, for example, a fragment, a cluster, a strand, a thread, a rope, a braid, a sheet, a coil, a tube, a cylinder, a textile, or a mold of an organ. In some embodiments, the fiber may be formed into a mold of an organ such as, for example, a trachea, a trachea and at least a portion of at least one bronchus, a trachea and at least a portion of a larynx, a larynx, an esophagus, a large intestine, a small intestine, an upper bowel, a lower bowel, a vascular structure, an artery, a vein, a nerve conduit, a ligament, a tendon, and portions thereof. In some embodiments, the fiber may be formed into the shape of a suture.

In some embodiments, the fiber may be formed into a fragment having an average length of about 1 μm to about 1000 μm, and an average diameter of about 0.1 μm to about 10 μm. Some non-limiting examples of average fragment lengths may include an average length of about 1 μm,about 5 μm, about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 75 μm, about 90 μm, about 95 μm, about 100 μm, about 105 μm, about 110 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1000 μm, or ranges between any two of these values (including endpoints). Some non-limiting examples of average fragment diameters may include an average diameter of about 0.1 μm, about 0.5 μm, about about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, or ranges between any two of these values, including endpoints.

In some embodiments, the fiber may be formed into a cluster. As used herein, the term “cluster” refers to an aggregate of fiber fragments, or a linear or curved three-dimensional group of fiber fragments. Clusters may have a range of shapes. Non-limiting examples of cluster shapes may include spherical, globular, ellipsoidal, and flattened cylinder shapes. Clusters may have, independently, an average length of about 1 μm to about 10,000 μm (1 cm), an average width of about 1 μm to about 10,000 μm (1 cm), and an average height of about 1 μm to about 10,000 μm (1 cm). It may be appreciated that any cluster dimension, such as length, width, or height, is independent of any other cluster dimension. Some non-limiting examples of average cluster dimensions include an average dimension (i.e. length, width, height, or other measurement) of about 1 μm, about 5 μm, about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 75 μm, about 90 μm, about 95 μm, about 100 μm, about 105 μm, about 110 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1,000 μm, about 1,500 μm, about 2,000 μm, about 2,500 μm, about 3,000 μm, about 3,500 μm, about 4,000 μm, about 4,500 μm, about 5,000 μm, about 5,500 μm, about 6,000 μm, about 6,500 μm, about 7,000 μm, about 7,500 μm, about 8,000 μm, about 8,500 μm, about 9,000 μm, about 9,500 μm, about 10,000 μm (1 cm), or ranges between any two of these values (including endpoints), or independent combinations of any of these ranges of dimensions. Clusters may include an average number of about 2 to about 1000 fiber fragments. Some non-limiting examples of average numbers of fiber fragments per cluster include an average of about 2 fiber fragments per cluster, about 5 fiber fragments per cluster, about 10 fiber fragments per cluster, about 20 fiber fragments per cluster, about 30 fiber fragments per cluster, about 40 fiber fragments per cluster, about 50 fiber fragments per cluster, about 60 fiber fragments per cluster, about 70 fiber fragments per cluster, about 80 fiber fragments per cluster, about 90 fiber fragments per cluster, about 100 fiber fragments per cluster, about 110 fiber fragments per cluster, about 200 fiber fragments per cluster, about 300 fiber fragments per cluster, about 400 fiber fragments per cluster, about 500 fiber fragments per cluster, about 600 fiber fragments per cluster, about 700 fiber fragments per cluster, about 800 fiber fragments per cluster, about 900 fiber fragments per cluster, about 1000 fiber fragments per cluster, or ranges between any two of these values, including endpoints.

EXAMPLES

To create the fiber comprising a polymer and 100 wt % bismuth based on the weight of the polymer shown in FIG. 5, the solution weight % and total weight for the solution without the bismuth were chosen. The mass of the solvent and polymer were then calculated, and the mass of the bismuth was calculated by taking 100% of the polymer mass. The polymer and solvent were mixed in a flask until homogeneous, and the contrast agent was then added and mixed until colloidal or very well dispersed. Scanning electron microscope (SEM) images were then obtained.

To create the fiber comprising a polymer and 400 wt % bismuth based on the weight of the polymer shown in FIG. 6, the solution weight % and total weight for the solution without the bismuth were chosen. The mass of the solvent and polymer were then calculated, and the mass of the bismuth was calculated by taking 400% of the polymer mass. The polymer and solvent were mixed in a flask until homogeneous, and the contrast agent was then added and mixed until colloidal or very well dispersed. Scanning electron microscope (SEM) images were then obtained.

The mechanical properties of fibers created as described above were also analyzed. FIGS. 7, 8, and 9 graphically illustrate comparisons of the ultimate tensile strength (UTS, in MPa), modulus, and elongation (%), respectively, of a fiber comprising polycaprolactone (PCL), and a fiber comprising PCL and 400 wt % bismuth (Bi₂O₃) based on the weight of the PCL. Generally, when adding hard particles to a soft matrix, one would expect the UTS and modulus of the resulting fiber to increase, and the % elongation to decrease. Surprisingly, the fibers in accordance with the present disclosure and their mechanical properties described in FIGS. 7, 8, and 9 displayed the opposite results. Compared to the fiber comprising PCL, the fiber comprising PCL and 400 wt % Bi₂O₃ displayed decreased UTS and modulus, and increased % elongation. These results were unexpected, and such mechanical properties may be useful over any previously made compositions, particularly for applications related to the repair, replacement, or treatment of any organ or tissue within the body, or for the proliferation or differentiation of cells outside the body.

FIG. 10 illustrates stress-strain data measured as elongation (%) versus engineering stress (MPa) of five fiber samples (Samples 1-5), each sample comprised of a 2:8 ratio of an polyethylene terephthalate to polyurethane blend without an added filler. In turn, FIG. 11 illustrates stress-strain data measured as elongation (%) versus engineering stress (MPa) of five fiber samples (Samples 1-5), each sample comprised of a 2:8 ratio of polyethylene terephthalate to polyurethane blend comprising 1,000 wt % tantalum. The filled samples illustrate that fibers comprising a filler (including a contrast agent) present at about 1,000 wt % can maintain sufficient mechanical integrity for use in the applications disclosed herein. Further, when the filler includes a contrast agent, it is apparent that the ability to have a fiber with a high wt % of contrast agent provides a much-needed benefit for non-invasively imaging the fiber. Further, it is unexpected that such a high amount of a filler (such as a contrast agent) can be incorporated into a fiber while maintaining this mechanical integrity.

While the present disclosure has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the disclosure in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the Applicant's general inventive concept.

Claims

1. A fiber comprising:

an electrospun polymer; and

a contrast agent present in an amount of at least about 1,000 wt % based on the weight of the electrospun polymer.

2. The fiber of claim 1, wherein the polymer is selected from the group consisting of polyethylene terephthalate, polyester, polymethylmethacrylate, polyacrylonitrile, silicone, polyurethane, polycarbonate, polyether ketone ketone, polyether ether ketone, polyether imide, polyamide, polystyrene, polyether sulfone, polysulfone, polycaprolactone, polylactic acid, polylactide-co-caprolactone, polylactide-co-glycolide, polyglycolic acid, polyglycerol sebacic, polydiol citrate, polyhydroxy butyrate, polyether amide, polydioxanone, derivatives thereof, and combinations thereof.

3. The fiber of claim 1, wherein the contrast agent is dispersed within the electrospun polymer.

4. The fiber of claim 1, wherein the contrast agent comprises a powder, the powder comprising particles having a diameter from about 10 nm to about 10 μm.

5. The fiber of claim 1, wherein the contrast agent is selected from the group consisting of barium, tantalum, tungsten, platinum, gold, bismuth, iodine, gadolinium, diatrizoate, metrizoate, ioxaglate, iopamidol, iohexol, ioxilan, iopromide, iodixanol, derivatives thereof, oxides thereof, salts thereof, and combinations thereof.

6. The fiber of claim 1, wherein the contrast agent is present in the fiber in an amount of about 1,500 wt % based on the weight of the electrospun polymer.

7. The fiber of claim 1, wherein the contrast agent comprises tantalum.

8. The fiber of claim 1, further comprising one or more of an electrically conductive material selected from the group consisting of gold, silver, iron, polyaniline, carbon black, polyacrylonitrile, graphene, and combinations thereof; a fluorescent material, a luminescent material, an antibiotic, a growth factor, a vitamin, a cytokine, a steroid, an anti-inflammatory drug, a small molecule, a sugar, a salt, a peptide, a protein, a cell factor, DNA, RNA, or a combination thereof.

9. The fiber of claim 1, having a length of about 5 μm to about 5m and a diameter of about 50 nm to about 50 μm.

10. The fiber of claim 1 formed into a shape selected from the group consisting of a fragment, a cluster, a strand, a thread, a sheet, a rope, a braid, a coil, a tube, a cylinder, a textile, and a mold of an organ.

11. The fiber of claim 1 formed into a fragment having an average length of about 1 μm to about 1000 μm, and an average diameter of about 0.1 μm to about 10 μm.

12. The fiber of claim 1 formed into a cluster having, independently, an average length of about 1 μm to about 10,000 μm, an average width of about 1 μm to about 10,000 μm, and an average height of about 1 μm to about 10,000 μm.

13. A method of making an electrospun fiber, the method comprising:

configuring a receiving surface to receive a polymer fiber;

applying a charge to one or more of the receiving surface, a polymer injection system, and a polymer solution ejected from the polymer injection system; and

depositing the polymer solution ejected from the polymer injection system onto the receiving surface;

wherein the polymer solution comprises a polymer and a contrast agent; and

wherein the contrast agent is present in an amount of at least about 1,000 wt % based on the weight of the polymer.

14. The method of claim 13, wherein the polymer is selected from the group consisting of polyethylene terephthalate, polyester, polymethylmethacrylate, polyacrylonitrile, silicone, polyurethane, polycarbonate, polyether ketone ketone, polyether ether ketone, polyether imide, polyamide, polystyrene, polyether sulfone, polysulfone, polycaprolactone, polylactic acid, polylactide-co-caprolactone, polylactide-co-glycolide, polyglycolic acid, polyglycerol sebacic, polydiol citrate, polyhydroxy butyrate, polyether amide, polydioxanone, derivatives thereof, and combinations thereof.

15. The method of claim 13, wherein the polymer is present in an amount of about 1 wt % to about 30 wt % based on the weight of the polymer solution.

16. The method of claim 13, wherein the contrast agent is present in an amount of about 1,500 wt % based on the weight of the polymer.

17. The method of claim 13, wherein the contrast agent comprises a powder, the powder comprising particles having a diameter from about 10 nm to about 10 μm.

18. The method of claim 13, wherein the contrast agent is selected from the group consisting of barium, tantalum, tungsten, platinum, gold, bismuth, iodine, gadolinium, diatrizoate, metrizoate, ioxaglate, iopamidol, iohexol, ioxilan, iopromide, iodixanol, derivatives thereof, oxides thereof, salts thereof, and combinations thereof.

19. The method of claim 13, wherein the polymer solution further comprises a solvent selected from the group consisting of acetone, dimethylformamide, dimethylsulfoxide, N-methylpyrrolidone, acetonitrile, hexanes, ether, dioxane, ethyl acetate, pyridine, toluene, xylene, tetrahydrofuran, trifluoroacetic acid, hexafluoroisopropanol, acetic acid, dimethylacetamide, chloroform, dichloromethane, water, alcohols, ionic compounds, derivatives thereof, and combinations thereof.

20. The method of claim 13, wherein the polymer solution further comprises one or more of an electrically conductive material, a fluorescent material, a luminescent material, an antibiotic, a growth factor, a vitamin, a cytokine, a steroid, an anti-inflammatory drug, a small molecule, a sugar, a salt, a peptide, a protein, a cell factor, DNA, RNA, or a combination thereof.

21. A fiber comprising:

an electrospun polymer; and

a contrast agent present in an amount of at least about 1,000 wt % based on the

weight of the electrospun polymer;

wherein the fiber is formed into a shape of a coil.

22. The fiber of claim 21, wherein the contrast agent comprises tantalum powder dispersed within the electrospun polymer.

23. The fiber of claim 22, wherein the electrospun polymer comprises a blend of polyethylene terephthalate to polyurethane blend in a 2:8 ratio.